Soap-molding apparatus



Nov. :13, 1928.

L. A. PALEY SOAP MoLDING APPATUS s sheetssne'et 1 Filed Mron 2:5.A 1922 GUFI.

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Nov.'l3, 1928. 1,691,899

L. A. PA'LEY i SOAP MOLDING APPARATUSv Filed March 23. 1922 3 Sheets-Sheet 3 rvnmowu /m/Z/v TOR LEWIS L PALY, or MANHAssEr, NEW Yom;

soar-Monnme APPARATUS.

'Application led March 23, 1922. Serial No. 546,089. I

This invention relates to an apparatus for the manufacture of soap, paraliin, wax, stearin, gelatin, cocoa butter, and other substances f which are liquid when hot and solidify on 5 cooling and hasreference more particularly l to an apparatus in which the substance is .ar-

tificially cooled until solidi-fied, pressed, and

wrapped while in a solid state.

' This application is a divisional application Vcarved from my Serial No. 370,441, led April 1, 1920.

As practiced at present, soap is prepared In the kettle by heating a mixture of fats and alkali, separating the glycerine, running the hot soap into crutchers where it is mixed with iilling materials,v running the hot soap from the crutcher into fram-es, cooling the frames naturally until t-he soap is solidiiied, stripping the sides from the frame, cutting the block of soap intohorizontal slabs, cuttlng ythe slabs into cakes, drying the cakes,

stamping the inscription-on the dried cakes,

and 4wrapping vand packing same. The present process requires about three Weeks to prepare the soap for sale after it leaves the.

crutcher, ties up considerable capital in soap standing inl the frames, requires a large amount of labor and iloor space, produces a large amount of scrap which has to be reworked and produces cakes of a low quality duc to their roligh surfaces, air holes, streaksV caused by segregation of filling materials, dark color and non-uniform weight.

An obj ect of this invention is to provide an apparatus for manufacturing soap which will greatly reduce the time, labor andspace required for molding the soap into cakes after it leaves the crutcher.`

Another object of this 'invention is to pro- 40 vide an apparatus for molding soap which willproduce cakes of a high quality. Afurther object of this invention is to O endless chain of molds moves continuously and the cakes in the molds are stampedduring the continuous movement thereof.l

Reference is to be had to the accompanyf ing drawings forminga part of this specilication in which it is understood that the l drawings illustrate only one form of the invention and in which Figure lis a side elevation of the apparatus with parts broken away to disclose the construction. l5 Figure 2 is a sectional view through the detto-pending application provide soap molding apparatus in which the chamber attached for use on special grades of soap.

Figure 3 is a sectional view through the machine on the line 3 3 of Figure 1.

'livery end of the niachine showing the drying' l Figure 4 is a sectional view through one of thestamping wheels.l I

Figures 5, 6, 7 and 8 are detail views of the buckets or molds.

Referring to the accompanying drawings' by numerals, inl which like numerals represent like parts in the several views, 10 indi- Cates a crutcher which is preferably surrounded by acket 11 so that steam or cooling water maybe passed around said crutcher, thus 'controlling the temperature of the contents. The soap from the kettle not shown, is

run into this crutcher and any suitable stirring mechanism, such as al screw 12, mixes the soap thoroughly with Various iilling materials. I preferably provide apair of crutchers for each cooling machine so that when one crutcher has become empty, the contents ofthe remaining crutcher ma be run into the endless chain of molds to e hereinafter described while the empty crutcher is ibeing re-illed and its contents mixed. `The two crutchers are connected with each other by means of a Y-shaped pipe 13, each arm of which is provided with a valve 14, so that one valve may be closed while the hot liquid soap is running out of the other crutcher.

The Y-shaped pipe 13 terminates at its lower end in one or more pipes 15 each of which empties directly into a feed box 16. An endless chain of buckets or molds collectively designated by the numeral 17 is movably mounted so as to ass through the feed box 16,'and becomes fil ed with the hot liquid soap flowing into the feed box 16. The rearward wall 18 of the feed box is curved forwardly so as to direct the stream of soap into the-chain of molds 17 in the direct-ion of motion of said chain. The front side of the feed box 16 has hinged to it by means of a spring hinge 19, a plate or scraper 20. This late rests obliquely on top ofthe mold chain 17 so that the soap is pressed into the molds and scraped level whilethe spring hinge allows a slight' movement on-said scraper to allow for slight inequalities :in the uppersurfaces of the molds After being filled with thehot liquid soap,

ber 22, the chambers 21 and 22 being connected at each end b caps 23 provided with openings through W ich thefmold chainV 17 passes. Any coolingmedium, such .as a solution of sodium or calcium chloride from a refrigerating apparatus, not shown, is iintroduced into the chamber 22 by means of an intake pipe 24 and is removed by means of` an outlet pipe 25. The direction of flow of the cooling medium is preferably counter-current to the direction of motion of the mold chai-n 17 so that a substantiallyconstant difference of temperature is maintained throughout the length of the coolin chamber between the cooling medium and t e soap, thus insuring a high cooling efficiency. Thus the soap is cooled, and solidified to cakes as it passes through the cooling chamber 21 and may be then stamped and'discharged from the molds.

In this form of apparatus, the molds are preferably made by die casting and are preferably but not necessarily constructed so that the cakes are cast on edge and an inscription ma be molded on each of the broad surfaces While the to edge is pressed into final shape by means o a series of dies arranged around the peripher of a wheel. Each mold consists of a si e wall 26, which ma have an y inscription 27 formed on each si e thereof, said wall being integral with a mold bottom 28. Lu 29 and 30 are formed on the lower side of t e bottoms 28, the lugs 29 being preferably two in `number and spaced apart so as to receive the lu 30 of the adjacent bottom therebetween. oles 31 and 32 pass through the lugs 29 and 301respectively, so as to re' v ceive pins 33 which pivotally connect the molds. lugs 29 and 30 in the mold bottom 28, said recess being adapted to receive the tooth 35 of y a sprocket wheel 36, A lon itudinal slot is formed on each edge of the si e walls 26 so as to receive the fiange 35 of a flexible win 36.

These wings 36 form the ends of 'the' mol and terminate on the edge abutting the adjacent `mold side wall 26, in an inwardl extending fiange 37 which causes the finislied l:cake of soap to have rounded edges. The flexible wings 36 normally are positioned slightly s rea a art but when the molds pass t rough t e feed box 1-6 to receive the hot` liquid soap, said wings are pressed together by the sides of the feed box so as to be substantially parallel. After receiving the hot I liquid soap,'the cooling chamber 21 becomes slightly wider so that the wings 26 spread slightly, thus ermitting the hot soap to settle somewhat in tlie mold.

Upon leaving the cooling chamber 21 the wings 36 are brought together into parallel position by the sides of a stamping ude 38, thereby pressing the soapslightly. n order to pressor stamp the .u per surfaces ofthe cakes intiofinal formas t ey leave the cooling (chambery 21, a massivewheel 39 is rotatably A recess 34 is formed between the mounted on a shaft 40 and the outer periphery of said wheel is provided with a plurality of recesses 41,-each of which is adapted to engageone of the side walls 26 so as to cause the rotation of'said lwheel as the mold chain moves.` The recesses 41 form a plurality of dies 42 which bear upon the Soap in the molds, and owin to the wei ht of the wheel, press the cake into its fina compact form. The outer surface of each of the dies 42 may have any shape mark or pattern desired to imprint on the ca e of soap. Thus in the example 'illustrated where finished cakes with rounded edges are desired, outstandin lips 43 are formed around the edges of t e surface of each die42, so that the desired shape of fin- Vished cake is obtained. The shaft 40 is rotatably mounted in slots 45 in brackets 46 so that 'the wheel 39 may rise slightly to accommodate itself to different cakes of soap. The brackets 46 are securedto standards 47 which are also secured to framework 48 and stamping guide 38. The framework 48 is secured to vertical standards 49 so as to support theV mechanism at the delivery end of the machine.

The'sprocketwheel, 36 is secured to a shaft 50 which is rotatably mounted in bearings 51 secured to framework 48. The shaft 5() is lrotated continuously by means of a. gear 52 pinion 53. The pinion 53 is secured to a power shaft 54 rotatably mounted in bearingsl 55 which are secured to framework 48. Any suitable power means such as an electric motor not shown is connected bysuitable means so as to cause they continuous rotation of the power shaft 54. A, sprocket'wheel' 56 similarvto the sprocket wheel 36, supports the mold chain 17 at the feed end of the machine, the wheel 56 beingsecured to a shaft 57 rotatably mounted in bearings 5 8. A suitable framework 59 supports the bearings 58 so as to position the mold chain 17 to pass through the feed box 16. The stamping guide 38 is preferably long enoufrhto hold the wings 36 ofthe molds parallel until just after they startaround the sprocket wheel 36 so that the flan es 37 will first grip the edges of the soap an vloosen it from the side wall 26 and bottom 28 of the adjacentmold. The win s 36'will then be released bythe stamping gui e 38 so as to snap routwardly and free themselves from the end of the cake, and/when the molds are upturned, the cakes of soap will Adrop onto a chute 60 and slide onto the endless belt 61 which deliversthe cakes directly to a .discharge point such as a standard wra ping machine, after which it is packed in oxes. The shield 62 deflects the cakes-so that the fall on edge on the endless belt 61. The be t- 63 secured toshaft 64, said shaft being rotat- I Iaby mounted in bearings 65. f it is desired to dry a special ty e of soap, a chute 60 (Fig. 2) delivers the ca es onto a lill) cross shaped distributer 166 vvhioh is` posin drying conveyor 67. f The-distributor 66 is mounted to reoiprotioned above awide, endless' cate-axially so as to ick up the ,cakes of soa as they slide down t echute 60?, and at eac endof its stroke it rotates through one uarter of 'a revolution so as to deposit the ca es on edge over the full width of the conveyor 67.

A shield 68 is mounted on a shaft 69 and is adapted to deflect the cakes on edge onto the distributor 66 `and tip outwardly about the i shaft 69 as the distributer 66 yrotates so as to positioned in said chamber between the tWo reaches of the conveyor 67'. The steam preferably but not necessarily flows in the direc tion opposite tothe direction of How of the air so as to provide an efficient transfer of heat from the steam to the air. After being dried, the cakes 70 are delivered from the conveyor 67 to another conveyor, not shown, which delivers the cakes to a dischargepoint,

` such as a standard Wrapping machine, aft-er which they are packed in boxes: The details of the drying chamber 71 and the mechanism which actuates the distributer 66 and shield 68 are more fully illustrated and described in my aforementioned Lco-pending application.

In operation, the hot soa-p from the crutcher lO'fiows through pipes 13 and 15'into feed vbox 16. The endless chain of molds 17 passes through the feed box 16 being filled With the hot soap, and then passes through the cooling chamber 21 where the soap is solidified to cakes. The cooling medium for accomplishing the solidication is admit-ted to the chamber 22. through pipe 24 and withdrawn through pipe 25. The inscription 27 forms animprint of the inscription on the cakes and a wheel 39 with dies 42, presses the ,u per edge of the cakes into final shape.' rlhe exible wings 36 aid in freein the cakes 70 from the molds as the mold cham 17 passes around v the sprocket wheel 36e-i and the cakes .slide down a chute 60 andfall` onto an endless belt 61 'which carries them to a standard wrapping machine after' which they 'are packed. If it is desired to dry 'the cakes before wrapping the cakes are delivered by a chute 60l onto a distributer 66 which deposits thecakes over the full lWidth of a drying conveyorf67. Thisl conveyor slowly carries the cakes through the drying chamber .71 where the cakes are-subjeaed; a as man of' moving warm, sin' i aftelfwhich they are delivered ont() v an. end? l less :belt which machine'.

I would sta-te in conclusion thatwhile the illustrated examples constitute a practical embodiment of my invention, I do not limit myself strictly to the details herein illusspirit of the invention as defined in the appended claims. y'

HavingY thus described my invention I claim as new and desire to secure by Letters Patent:

1. In an apparatus for the manufacture of soap and the like, an endless chain of molds, the side wall of each mold also serving as a side Wall of an adjacent mold, the

' bottom of each mold-being removable and securedto the side Wall of the adjacent mold,

means for pivotally connecting said molds,

a' pair of flexible Wings associated with each mold adapted to form end Walls for each. mold, a plurality of sprocket'wheels adapted to receive said-endless chain of molds, means for rotating one of said sprocket wheels so as to cause a continuous movement of saidv -endless chain of molds, means formtroduc-l mg hot llquid soap into said chain-of molds,

means' for cooling the soap in said endlessl chain of molds as said chain -is moved, so to form cakes, means for stamp-mg sald cakes carries|` them to the wrapping" 4tra-ted since manifestly the same can be convsiderably varied Withoutdeparting fromthe f of soap said molds after they are cooled,

and means for discharging said cooled'cakes. of soap from said moldsw 1 A 2. 'In an apparatus for the manufacture of soap and the like, an endless chain of molds, the side Wall of each-mold also serving as a side Wall of an adjacent mold, the bottom` of each mold being removable and secured to the-side Wall of the adjacent mold, means for pivotally connecting said molds, a pair of. iexible Wings associated With each mold adapted to formend AWalls for each mold, a plurality of sprocket Wheels adaptedto receive said endless chain of molds, means for i rotating one of said sprocket Wheels so as to cause a continuous movement of said endless chain ofmolds, means for introducmg hot Aliquid soap into, said chain of molds, means for cooling the soap in said endless chain of molds as said chain is moved, so as to form cakes, means for stamping said cakes of soap in said molds after they are cooled as said chain ofy molds moves continuously, and

means for discharging said cooled cakes of soapv from said molds. y

3. In an apparatus for the manufacture of soap and the like, 4an endless chain of molds,

means for introducing-hot liquid soapinto said molds, means lfor continuously lmoving HID said molds of soap, means for cooling the soap `insaid molds so as to form cakes, a rotatably mounted Wheel engaging said mold chain and adapted to press vsaid cakes of soap in said molds as said molds are moved continuously, and flexible means associated with said molds adapted to aid in discharging said cakes l presse of soap from said molds after they are 4. In an apparatus for the manufacture of' soap and the. like, an endlesschain of molds,

adapted to press said cake of soap in said mold's as said molds are moved continuously, and a pairof flexible Wings forming'the end Walls of each mold, said iiexible Wings being adapted to automatically discharge said cakes of soap from said molds as said mold chain is moved continuously. .i

5. In an apparatus `for the manufacture of soap and the like, an endless chain of molds, means for introducing hot liquid soap into said molds, means for continuously movingzsaid molds of soap, rmeans for cooling the soap in said molds so as to form cakes, means for pressing said cakes of soap in said .molds as said molds are moved continuously, means for discharging said cakes of soap from said molds after they are pressed,

c and means for drying saidcakes of soap after they are discharged from said molds.

6. In a'n apparatus for the manufacture of soap and the like, an endless chain of molds,

- means for introducing hot liquid soap into said molds, means for continuously moving said molds of soap, means for cooling the soap in said molds so as to 'form cakes, means for pressing said. cakes of soap in said molds as said molds are moved continuously, a pair ofiflexible wingsforming the end Walls of each mold, saidilexible wings being. adapted to aid in vautomatically discharging said cakes of soap from said molds during the continuous motion thereof, and means for drying said cakes of song) after they are dis? charged from said mol 7. In an apparatus for the manufacture of soap and the like an endless chain of molds adapted to receive hot liquid soap, means for supplying hot liquidl soa to said molds, means for cooling and ,soli ifying the soap in said molds, and a pair of flexible wings associated with each mold adapted t0 form the end walls of said mold, ,said flexible wings serving to aid in discharging the cakes of soap from said molds as said molds are moved.

` 8. In a soa marking machine an endless chain of mol boxes each ada ted to containl a cake of material to be mar ed, means for modifyin the temperature of the cakes in the mol boxes, a markingvdie rotatably mounted with respect toA said boxes, means for causing the marking 'die to move at the same lineal speed as the mold boxes and to -coact therewith for markin a cake in a mold box, and means for yielingly pressing said marking die toward the cake of material to be marked.

9. In an apparatus for the manufacture .of soap and the like, a series of molds, means for introducing hot liquid soa-p ,into said molds, means for cooling the air through which the hot molds ass, means for continuousl moving sai moldsthrough the cooled air so as to solidify said soap to form cakes, a rotatably mounted wheel engaging said molds and adapted to stamp the free surfaces of cakes into finished form as the molds move continuously, and means for removing the cakes from 'said molds.

10. In a molding machine, a series of movable molds adapted to receivea hot liquid substance, means for cooling the air through which the hot'molds pass, means for moving said molds through the cooled air so as to solidify said substance to cake form, a die positioned adjacent said molds after said molds leave the cooling element, said die haw `ing a with said series of molds and ada ted to move with said molds for a selected istance A.

lUfi

in contact with said substance so as to modify theshape of the cakes in said molds,

and means for ejecting the cakes from 'the molds.

12. In a molding machine, a series of molds adapted to move over a continuous path and to receive a hot liquid substance, means for cooling the air through which the molds pass to form solidified cakes, a. series of dies adapted to move with the molds along only a portiop of the path of said molds, said dies bein adapted to successively press against the su stance and modify the shape of .the cakes, and mea-ns for ejecting Ythe cakes from the molds. Y i

13. In a molding a paratus an endless chain ofemolds, means or introducing a hot. liquid substance into sai-d molds, means for cooling the air through which the molds con'- taining the hot substancemove, means for moving said chain of molds with a continuous motion through the cooled air so as to cool said substanceto solid cakes, means for subjecting said cakes to pressure While in said molds, and means for ejecting the cakes from the molds. y

14. In an apparatus for the manufacture of soap and the like, an endless cha-in of molds, a plurality of sprocket wheels adapted to receive said endless chain of molds, means for rotating one of said sprocket wheels so 'as to cause a continuous movement of said endless chain of molds, means for introducing hot, liquid soap into said chain'of molds, means for cooling the soap in said molds during the movement' thereof so as to form solid cakes, means for pressing an eX- posed surface ofvsaid cakes of soap in said molds, and means for discharging said cooled and pressed cakes of soap from said molds.

LEWIS A. PALEY. 

